ZODIAC CH 601 Series Kit Aircraft

Transcription

1 ZODIAC CH 601 Series Kit Aircraft THE FOLLOWING IS A DRAFT MANUAL This manual has been written and published strictly for informational purpose. It has been prepared as a guide to facilitate the assembly of the ZODIAC CH 601 kit aircraft. It is published to supplement (and not replace) the Zenair drawings and manuals. If a discrepancy arises between this informational manual and the Drawings, the Drawings always take precedence. All pictures, diagrams, drawings or graphs, are used for general identification only, and are not to be taken to represent technical drawings or replicas of exact parts. You should not consider the educational material in the manual to be the practice of general aviation nor is it intended for this manual to be a complete account of sheet metal aircraft technology: It is limited to the scope of the ZODIAC CH 601 aircraft assembly This manual is not intended to replace, substitute for or supersede any technical information contained in the ZODIAC CH 601 Drawings and Manuals by Chris Heintz, or other designer s specifications. Zenith Aircraft Company (ZAC) nor its authors guarantees the accuracy or completeness of any information published herein and neither ZAC nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This guide is printed with the understanding that ZAC and its authors are supplying information but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. Copyright, Zenith Aircraft Company

2 ZODIAC CH 601 6T1-6 6T1-7 6T1-4 Rear 6T1-5 6T1-3 Front Tip Rib 6T2-4 6T1-1 6T2-3 6T2-6 Fiberglass Tip 6T1-2 6T2-1 6T2-2 ZODIAC CH 601 Drawing Rev. Description: (3/00) STABILIZER Zenith Aircraft Company : Mexico Memorial Airport, PO Box 650, Mexico, MO USA (573) FAX:

3 STABILIZER ASSEMBLY WORK REPORT Step Drawing page Sequence Check Part number & Description Qty Reference 1 [ ] 6T2-3 Rear Spar attachment t= T2, 6F15 2 [ ] 6T1-4 Rear Spar t= T1, 6T2 3 [ ] 6T1-6 Upper Doubler t= T1 HD 4 [ ] 6T1-7 Lower Doubler t= T1 HD 6 [ ] 6T2-6 Shim t= T2 8 [ ] 6T1-3 Front Spar t=.025 l= T2, 6T3 8 [ ] 6T1-5 Front Spar Cap Doubler t= T1, 6T2 11 [ ] 6T2-2 Attachment Doubler t= T2 12 [ ] 6T2-1 Front Spar Attachment t= T2 15 [ ] L ANGLE t=.025 l=4ft 1 6T2 16 [ ] 6T1-2 Center Ribs t=.016 (3R+3L) 6 6T1, 6T2 18 [ ] 6T1-1 Tip Ribs t=.025 (R+L) 2 6T1, 6T2 21 [ ] 6T2-4 Stabilizer Skin t=.016 dl=875, l= T2 Info [ ] FTT Fiberglass Tail tips 2 Info [ ] FTT Aluminum Reinforcement Rib 2 SIGNATURES: Builder date Inspector date ZENITH AIRCRAFT COMPANY Print Date: 10/24/01 ZODIAC CH 601

4 REAR SPAR DOUBLERS T-35 The Rear Spar Attachment fits on the back side of the Rear Spar in order to bolt the Stabilizer to the fuselage. Before installing, the side flanges are cut down from 22mm to 3mm on the overlapping portion with the Rear Spar this is to make clearance for the front bottom of the elevator during down deflection. The 20mm cutout from the centerline in the bottom of the Rear Spar Attachment is to make room for the bottom elevator cable during up deflection. The Upper and Lower Doubler are Clecoed to the Rear Spar before positioning the Center Ribs. Later, when the Center Ribs are positioned they will overlap on top of the Doubler with a rivet through the middle of the overlap of the Rib flange with the Doubler. 1. LAYOUT the cutout on the Rear Spar Attachment 6T2-3: mark a 3mm offset line above the web (the web is the flat area between the flanges). From the bottom, mark the corner at 29mm and the top at 19mm, connect the slop line (bottom left on drawing 6T2 shows the side flange cutout reference from the top edge) CORNER RELIEF HOLE: The edges of the corner relief holes are tangent to the sides of the cutout. Carefully center-punch the center of each ¼ hole above the 3mm line (approximately 32mm from the bottom). Drill the holes before cutting the side flange. SAW: With the part clamped in a vise (protect the part from the sharp edges of the steel vise jaws) use a hacksaw to carefully cut above the line. Be prepared to back off the pressure on the saw when it cuts through the relief hole or it will cut and mark into the opposite side! File to the line to remove the saw marks for a smooth finish. For the middle opening, the 12mm radius can be contoured with a large half round file instead of drilling a large 22mm hole. 2. Identify and label the top and front side of the Rear Spar 6T1-4: the top flange is 5 degrees closed and points toward the rear. The bottom flange of the Z shaped spar points to the front and is 5 degrees open (larger than 90degrees). Mark the aircraft center at 1100mm from the ends perpendicular to the bottom flange. 3. With the Rear Spar 6T1-4 on the workbench position the Upper Doubler 6T1-6 underneath the top flange. LAYOUT: Mark the rivet line on the Upper Doubler on the flange that overlaps on top of the spar web. The side flange is drilled later from the top through the skin. Also mark the aircraft center line at 610mm from the ends. The end holes are at 10mm from the ends of the Doubler with the next two 20mm spacing. AMP: To center the Doubler on the Spar, super-impose the centerline of the Doubler with the aircraft centerline of the Rear Spar. DRILL & ECO: Drill & Cleco the three holes at each ends of the Doublers into the Rear Spar web. 4. Cleco the Lower Doubler 6T1-7 to the bottom flange of the Rear Spar 6T1-4 AMP: Mark the rivet line, locate the aircraft center line, layout the end holes at 10mm from the ends and the next two holes as 20mm spacing. Center the Doubler on the Rear Spar clamp before drilling the three holes at each ends into the Rear Spar Web. ZENITH AIRCRAFT COMPANY Print Date: 10/24/01 ZODIAC CH 601

5 ZODIAC CH 601 TRIM 6T2-3 CORNER RELIEF HOLE 1/4 HOLE TANGENT TO EDGE BOTTOM TOP 20 mm 19 mm 10 mm 3 mm 6T2-3 REAR SPAR ATTACHMENT t= REQ. 12 mm RADIUS 18 mm 6T1-4 REAR SPAR t=.025 dl=114, l= REQ. 6T1-6 6T1-7 LOWER DOUBLER t=.032 dl=34, l= REQ. UPPER DOUBLER t=.032 dl=34, l= REQ CENTER UPPER AND LOWER DOUBLERS ON THE REAR SPAR. Right Left A BACK SIDE A5 Bottom Top ZODIAC CH 601 Drawing Rev. 3/00 Description REAR SPAR ATTACHMENT T-36

6 REAR SPAR ATTACHMENT T-37 A Shim of the same thickness as the Upper Doubler fits underneath the Rear Spar Attachment. Finish drilling the Doublers to the Rear Spar by dividing the distance between the Center Ribs stations for a pitch of 40mm. The holes at the Rib stations are drilled later on the middle of the overlap of the Rib flange with the top and bottom Doublers. 5. AMP the Rear Spar Attachment 6T2-3 to overlap on top of the Upper Doubler 6T1-6. Slide the.040 Shim 6T2-6 in-between the Spar web and the Attachment. CHECK: a) The top of the Rear Spar Attachment stops at the bend tangent line of the Upper Doubler. b) The sides are at 90degrees to the bottom of the Rear Spar. c) The parts are centered on the aircraft center line (equal distance from the left or right ends of the Spar). LAYOUT: a) Total of 25 A5 rivets into the Attachment (five rows of 5A5): the top and bottom rows are through the Doublers with 3 rows into the Shim. b) 4 A5 rivet in one vertical column of rivets into the Shim and Spar on both sides of Rear Spar Attachment. DRILL & ECO: With #20 6. RIB POSITION TEMPLATE: The left and right sides of the Stabilizer are symmetrical, also the rivet pitch is the same in both the Top and Bottom Doublers. On a 4ft sheet metal strip (approximately 30mm wide) or on a yard stick, layout the following rib stations at: 160, 320 and 360mm. Clearly label the zero reference end from which the rib stations are set - the template is used by lining up the zero reference with the aircraft center line. This template will also be used to layout the rib stations on the Front Spar 6T1-3 and on the Stabilizer Skin 6T LAYOUT: Use the RIB POSITION TEMPLATE with the zero reference on the aircraft centerline to mark the ribs station lines on both Doublers (top and bottom right and left sides). It may be easier to remove the Rear Spar Attachment to lay the zero end of the template on the Rear Spar center line. RIVET PITCH: Divide the distance between the rivet station for a pitch of 40mm. (using a 40mm pitch template). Also divide the distance between the Rear Spar Attachment and the first Rib at station 160 for a pitch of 40mm. DRILL & ECO: #20 drill bit. Before drilling, clamp or firmly pinch the Doubler against the Rear Spar flange. Wait to drill the holes at the Rib stations, they are drilled later when the Ribs are positioned to center the hole on the middle of the Rib flange with the overlap of the Doublers. ZENITH AIRCRAFT COMPANY Print Date: 10/24/01 ZODIAC CH 601

7 ZODIAC CH 601 6T2-3 6T2-6 HD SHIM t= X78 1 REQ. 6T1-4 6T1-6 6T1-7 CENTER THE SHIM AND REAR ATTACHMENT ON THE SPAR. 6T2-6 5 A5 IN DOUBLER 6T2-3 6T1-6 6T2-6 6T A5 IN ATTACHMENT 4 A5 IN SHIM ZODIAC CH 601 Drawing Rev. Description: 1st Edition: 7-96 REAR SPAR ATTACHMENT T-38 (3/00) Zenith Aircraft Company : Mexico Memorial Airport, PO Box 650, Mexico, MO USA (573) FAX:

8 FRONT SPAR DOUBLERS & ATTACHMENTS T-39 The Front Spar Cap Doublers are Clecoed against the inside web of the Front Spar Note: Unlike the Rear Spar, the top and bottom flanges of the Front Spar are bent at the same angle. The Front Spar Attachment is a 22mm wide angle reinforced by two Attachment Doublers. A plywood template the width of the fuselage (219mm) is used to correctly space the two Front Spar Attachment. 8. LAYOUT: The Front Spar Cap Doublers 6T1-5 are Clecoed inside the Front Spar 6T1-3 to the web, the side flanges are drilled later through the Stabilizer Skin 6T2-4. Mark the rivet line in the middle flange as well as the aircraft centerline at 610 from the ends. The end holes are at 10mm from the ends with the next two holes 20mm apart. AMP: Front Spar Cap Doublers to the side flange of the Front Spar. DRILL & ECO: Drill & Cleco the six end holes with #20 in both Front Spar Cap Doublers. 9. Carefully cut a plywood template 219mm wide with parallel sides at 90 degrees to the top edge. LAYOUT: Draw the aircraft center line at 110mm down the middle of the plywood block AMP the 219mm template on the front side of the Front Spar by superimposing center lines (the center line on the block over the aircraft center line on the Front Spar). CHECK: Use a square to check that the ends of the Block are at 90 degrees with the spar. 11. Drill and Cleco the Attachment Doublers 6T2-2 against the sides of the template with 3 #20. REMINDER: the top and Bottom holes are also through the Cap Doublers on the reverse side. 12. Remove the block and clamp the Spar Attachment 6T2-1 to the Doubler 6T2-2 flange. a) Position the top and bottom holes through on the intersection of center lines with Front Spar Cap Doublers. b) Add three #20 drilled holes evenly spaced between the two end holes. 13. FILE the top edge of the Doublers to avoid interference with the Stabilizer Skin 6T2-4 (wedge shaped taking off approximately 3mm at the front). ZENITH AIRCRAFT COMPANY Print Date: 10/24/01 ZODIAC CH 601

9 ZODIAC CH 601 CENTER THE FRONT DOUBLERS ON THE FRONT SPAR 6T1-5 FRONT SPAR CAP DOUBLERS l=1220 t= REQ T1-3 FRONT SPAR l=2200 t= REQ. FILE TO FIT PROFILE 219 mm 3 A5 5 A5 6T2-2 ATTACHMENT DOUBLER l=75 t= REQ. USING A PIECE OF WOOD, FIRST POSITION BOTH 6T2-2 DOUBLERS 6T2-1 FRONT SPAR ATTACHMENT l=105 t= REQ MARK RIB POSITIONS ON FRONT SPAR 360 ZODIAC CH 601 Drawing Rev. Description: 1st Edition: 7-96 FRONT SPAR ATTACHMENT T-40 (3/00) Zenith Aircraft Company : Mexico Memorial Airport, PO Box 650, Mexico, MO USA (573) FAX:

10 FRONT & REAR SPAR T-41 Finish drilling with #20 the Front Spar Cap Doubler to the Spar web by dividing the distance between the rib stations with pitch ECO: Use the rib position template to layout the rib stations. Divide the distance inbetween the rib stations using a 40mm pitch template. The holes at the Rib stations are drilled later through the rib flange. SUGGESTION: Extend the rib station line into the radius of the doublers. Later when the ribs are positioned, the line will be visible past the edge of the rib flange and is used to center the rib. NOTE on the STABILIZER RIBS: The End Rib 6T1-1 is symmetrical about the longitudinal axis, the Center Ribs 6T1-2 are also symmetrical about the longitudinal axis: the front flange is at 90 degrees to the longitudinal axis. The front of the Rib is wider than the rear of the Rib: the Front Spar 6T1-3 is 84mm wide and the Rear Spar is 80mm wide. The front of the Rib can be identified by the position of the tooling hole in the Rib web closest to the flange. A test is to hold the Center Ribs against the End Ribs back to back hold the aft flange 18mm from the end of the full Rib as shown in the top left diagram on drawing 6T1 (the top flange of the Rear Zee is flush with the aft edge of the End Rib).Left and Right ribs are similar, the Ribs are positioned on the skeleton with the flanges facing outboard. ZENITH AIRCRAFT COMPANY Print Date: 10/24/01 ZODIAC CH 601

11 ZODIAC CH601 FRONT SPAR T1-1 BOTTOM SIDEA5 PITCH 40 6T1-1 6T1-1 A5 PITCH 40 REAR SPAR BOTTOM SIDE T1-1 6T1-1 6T1-1 PITCH 40 BETWEEN THE RIBS (Divide distance between intersection holes and end holes) ZODIAC CH 601 Drawing Rev. Description: 7-96 ATTACHMENT DIMENSIONS T-42 (3/00) Zenith Aircraft Company : Mexico Memorial Airport, PO Box 650, Mexico, MO USA (573) FAX:

12 RIBS T-43 First Cleco the Center Ribs between the Front and Rear Spar, then add the End Ribs. The position of the End Ribs will determine the position of the Stabilizer Skin: the End Ribs are positioned flush with the aft edge of the top flange of the Rear Spar. Note: The bottom side of the Stabilizer Skin is shorter than the top side. - the bottom aft edge of the skin is flush with the Spar web, the middle diagram on drawing 6T2 shows the Stabilizer skin and the Rear Spar, (also called the Rear Z!). Cut the two holes for the Attachment Doublers in the bottom side of the Stabilizer Skin. 15. Prepare the Front and Rear Spar by installing the short length of L Angles at each end of the spars to attach the End Ribs 6T1-1. LAYOUT: The L Angles are Riveted on the front side of the Spars with 2 A4 rivets into the Spar web. NOTE: The L angle will rivet inside the End Rib cut the length of the L angles to the width of the spar web (distance between the upper and lower bent tangent line). 16. Cleco the Center Ribs 6T1-2 one at a time first to the Front Spar then to the Rear Spar. MARK: the flange center line on the inside for the front and rear flange. CENTER: Start with rib at station 160, center the Rib on the Spar between the top and bottom flange by holding the rib between your thumb and forefinger to feel the rib flush with the edges. Clamp in place with one clamp on the Doubler. The rivet hole is on the split middle of the overlap of the rib flange with the Doubler. Before drilling, use your finger to push the rib clear of the chuck; drill through the flange into the doubler and spar. Cleco and drill the second hole. Remove and label the rib to repeat the procedure on the remaining Ribs. Layout the rib stations on the Rear Spar using the rib position template to drill the ribs. RIVETS: 2A5 at the intersection with the Doublers. 2A4 in the Spar Web between the doublers, see drawing 6T2 bottom left diagram. 17. Cleco the Ribs to the Front and Rear Spars. NOTE: At rib station 360 the spars are drawn together by the thickness of the doublers 18. Position the End Ribs 6T1-1 flush with the aft edge of the top flange of the Rear Spar. CHECK: The distance from the Front Spar (web) to the front of the End Rib is approximately 110mm. DRILL: Two holes #30 in each L Angles and the Rib web. 19. Deburr, apply the corrosion inhibitor (zinc chromate primer) if desired, and rivet the skeleton together. ZENITH AIRCRAFT COMPANY Print Date: 10/24/01 ZODIAC CH 601

13 ZODIAC CH 601 6T1-2 CENTER RIBS t=.016 3L & 3R BOTTOM SIDE A5 PITCH 40 2 x A4 (L) ANGLE 2 X A4 6T1-1 END RIBS t= REQ. approx. 110 mm. 2 x A4 Leading Edge Reference Line PRE-DRILL SKIN CUT HOLES FOR THE SPAR ATTACHMENT bottom of skin WORKBENCH A4 PITCH 40 BETWEEN RIBS A4 Pitch 70 Leading Edge Reference Line PRE-DRILL FOR RIBS top of skin 6T2-4 STABILIZER SKIN t= REQ. ZODIAC CH 6O1 Drawing Rev. Description: 1st Edition: 7-96 STABILIZER SKIN T-44 (9/97) Zenith Aircraft Company : Mexico Memorial Airport, PO Box 650, Mexico, MO USA (573) FAX:

14 SKIN BOTTOM SIDE T-45 Fit the bottom side of the Stabilizer Skin first. Work with skeleton upside down with the skin overhanging down over the side of the work bench. Reference the Skin along the aft edge of the Spar checking the center line of the bent leading edge radius against the Rib. Level the assembly by blocking under the End Ribs and start drilling from the center out along the Rear Spar. Drill the Ribs and the Front Spar starting at the center and moving out towards the ends. Rivet the bottom side before starting on the top side. 20. HANDLE THE SKIN WITH CARE: The best way to move the Skin is to grab hold of the Skin between your fingers along the rear edge (top side or bottom is immaterial). Keep your arms well separated to help support the Skin evenly. The same technique is used when two people move the Skin; however one persons can handle the Stabilizer Skin very effectively. 21. Identify the bottom side of the formed Stabilizer Skin. Confirm by measuring the distance between the aft edge of the skin to the middle of the bent radius of the leading edge of the Skin against the same measure on the Rib (remember to measure from the spar web), the bottom side is shorter by approximately ¾ CUTOUT for the front Attachment Doublers: Mark the aircraft center line and the position of the cut-out to clear the two Front Spar Attachments 6T2-1 on the bottom side. Drill 3 corner relief holes (1/4 ) and cut in-between or use a round rat tail file to connect the holes! 22. Use the Rib positioning template to mark the rib center line on the skin, and mark the front and rear spar center line on the skin. Layout the rivet pitch and drill pilot with #40 drill bit. 23. Position the Skin over the skeleton with the Attachment brackets through the cutouts. Duct tape the rear edge to the Spar web to hold the Skin flush with the aft edge of the Spar. LEVEL: Slide 1x2 blocks under the End Ribs to remove any twist in the flexible skeleton. CHECK: The position of the center line of the leading edge bend radius against the End Ribs. DRILL & ECO: A4, start at the center and back drill into the Rear Spar alternating between the left and right side working your way to the tips. Work your way up the Ribs and start drilling the Front Spar starting at the center working towards the tips. RIVET: With A4, rivet head on the.016 Skin. 24. Turn the assembly over and slide a 1 x2 board underneath the End Ribs to clear the Attachment brackets above the work bend. STRAPPING: Run the strap underneath the workbench and over the Stabilizer assembly. Ratchet type straps are easy to adjust and can be set up ahead of time. ZENITH AIRCRAFT COMPANY Print Date: 10/24/01 ZODIAC CH 601

15 ZODIAC CH 601 AFTER ATTACHING SKIN TO THE SPARS, DRILL HOLES THROUGH ALL THE RIBS A4 PITCH 70 BOTTOM SIDE A4 PITCH 35 1" x 2" Wood Block PUSH ON 2x4 SUPPORT TO FOLD THE SKIN OVER THE STABILIZER AND RIBS ZODIAC CH 601 Drawing Rev. Description: 1st Edition: 7-96 SKIN POSITIONING T-46 (3/00) Zenith Aircraft Company : Mexico Memorial Airport, PO Box 650, Mexico, MO USA (573) FAX:

16 SKIN TOP SIDE T-47 Handle the Skin with care, use a 1 x2 8 ft. long to help support the Skin when folding the top side of the Skin over the ribs. Slide another 1x2 underneath the straps just ahead of the Front Spar to gently support the Skin. Slowly tighten the straps until the Skin lays flat. 25. Use straps to hold the Top side of the Skin on the Skeleton. HANDLING: To push the Skin down on the skeleton, take hold of an 8 foot 2 x4 along the sides, hold it up against the Skin and gently lower the Skin down. Partially tighten the straps. Add another 1x2 just in front of the Front Spar for added support. 6 straps is more than adequate! LEVEL: Block the front of the End Ribs to eliminate twist. Use a level to check both ends. 26. Mark the rivet lines for the front and rear Spar. Use the rib positioning Template to layout the position of the Ribs. RIVETS +PITCH: a) A4 pitch 40 through the Front Spar. b) A4 pitch 60 through the Ribs. c) Drill #40 Pilot holes. 27. Clamp the 6 ft (1830mm) Piano Hinge between the Skin and the Rear Spar, centered on aircraft center line. RIVETS + PITCH: A4 through the Rear Spar and Piano Hinge. (Locate the end holes at 10mm from the end of the Hinge). DRILL: #30 RIVET: A4 28. Add the Fiberglass tips inside the skin. PITCH: Draw a line at 10mm from the end of the Skin and duplicate the rivet pitch in the End Rib by sighting across. DRILL & ECO: #30 The Skin to the Fiberglass Tip. 29. Add the Tip Rib inside the rear ends of the Fiberglass Tips. DRILL + ECOS: #30 Pitch Rivet the tips with A4. 10/24/01: ZAC Engineering/601 manual/stab-tail1.doc ZENITH AIRCRAFT COMPANY Print Date: 10/24/01 ZODIAC CH 601

17 ZODIAC CH 601 USING STRAPS AND 1X2 BLOCKS SECURE THE SKIN TO THE STABILIZER SKELETON ZODIAC CH 620 Drawing Rev. Description: 3/00 SKIN POSITIONING T-48 Zenith Aircraft Company: Mexico Memorial Airport, PO Box 650, Mexico, MO USA (573) FAX:

18 INFORMATION SHEET TITLE STABILIZER Tail Tips Fiberglass Fairing (FTT) REFERENCE: 02/98 (3/00) PAGES: 1 The length of the Stabilizer Skin 6T2-4 at 2245mm is made longer than the skeleton, the overhand is to rivet the Fiberglass Tips underneath the Stabilizer Skin. Build and rivet the Stabilizer assembly by centering the skeleton in the middle of the Skin, split the overhand evenly between the left and right side. The Fiberglass Tips are positioned inbetween the top and bottom overhand of the Stabilizer Skin flush with the leading edge at the front. Drill and Cleco a rivet line 10mm from the edge of the skin by duplicating the rivet pattern of the End Rib. With the Tip Clecoed to the Skin position the aluminum FTT Stabilizer Fiberglass End Rib inside the rear portion of the Fiberglass Tips. Trace the position of the Rear Zee on the front of the Rib, remove the Tip to drill the Rib flush with the edge of the Tip. Drill the Tip Rib to the End Rib 6T1-1 with two A4. Use A4 to rivet the Tip to the Skin. ELEVATOR: The Elevator will fit in between the Fiberglass Tips, the trailing edge of the Elevator is not flush with the end of the Fiberglass Tips. SUGGESTION: Before installing, file the edge of the Fiberglass tips to remove any rough surface. COMMENT: The Fiberglass tips are symmetric, the top and bottom are the same, the left and right sides are the same. However there may be noticeable difference between the side edges, this is most noticeable when the edges are laid flat on the workbench: the overhand of the skin will cover any irregularities. TIP: Cut the bottom rear of the End Rib 6T1-1 on a diagonal between the bottom aft edge and the top aft edge of the Stabilizer Skin, this is to avoid possible interference with full down Elevator deflection. NOTE: The front corners of the aluminum FTT Rib are cut back, this is the same part as the Elevator Rib 6T3-1 before the front flange is bent.